Method of making a golf ball incorporating at least one elongated thermoset layer

ABSTRACT

Method of making a golf ball comprising: providing a subassembly and a thermoset polymer composition; partially curing the thermoset polymer composition and elongating same while in a partial cure state; forming a layer about the subassembly comprising the thermoset polymer composition; and further curing the thermoset polymer composition. A moldable thermoset polymer composition may be elongated while in state of partial cure. The thermoset polymer composition may be stepwise elongated by: stretching a thermoset polymer composition in at least one plane while in partial cure state and before forming into first and second half shells; forming the thermoset polymer composition into first and second half shells and elongating the thermoset polymer composition in three dimensions while in the partial cure state and before mating the first and second half shells about the subassembly; and mating the first and second half shells about the subassembly and forming a stepwise-elongated thermoset layer.

FIELD OF THE INVENTION

Methods of stretching or otherwise elongating golf ball compositions andincorporating same in golf balls, and the golf balls made by suchmethods.

BACKGROUND OF THE INVENTION

Conventional golf balls can be divided into two general classes: solidand wound. Solid golf balls include one-piece, two-piece (i.e., singlelayer core and single layer cover), and multi-layer (i.e., solid core ofone or more layers and/or a cover of one or more layers) golf balls.Wound golf balls typically include a solid, hollow, or fluid-filledcenter, surrounded by a tensioned elastomeric material, and a cover.

Examples of golf ball materials range from rubber materials, such asbalata, styrene butadiene, polybutadiene, or polyisoprene, tothermoplastic or thermoset resins such as ionomers, polyolefins,polyamides, polyesters, polyurethanes, polyureas and/orpolyurethane/polyurea hybrids, and blends thereof. Typically, outerlayers are formed about the spherical outer surface of an innermost golfball layer via compression molding, casting, or injection molding.

From the perspective of a golf ball manufacturer, it is desirable tohave materials exhibiting a wide range of properties, such asresilience, durability, spin, and “feel,” because this enables themanufacturer to make and sell golf balls suited to differing levels ofability and/or preferences. In this regard, playing characteristics ofgolf balls, such as spin, feel, CoR and compression can be tailored byvarying the properties of the golf ball materials and/or addingadditional golf ball layers such as at least one intermediate layerdisposed between the cover and the core. Intermediate layers can be ofsolid construction, and have also been formed of a tensioned elastomericwinding. The difference in play characteristics resulting from thesedifferent types of constructions can be quite significant.

In one approach, a “stiffer, as opposed to springy” material wasproduced by stretching cross-linked polymeric bands, skins or bladdersand applying same over or about a core. See, e.g., U.S. Pat. No.6,042,489 of Renard et al. at Col. 2, ll. 24-26. The cross-linkedmaterial crystalized under the mechanical tension or strain ofstretching and resulted in the stiffer material. See, e.g.,Mechanically-Induced chemical Changes in Polymeric Materials, Caruso etal, Chem. Rev., Oct. 14, 2009 at § 3.2.1.

However, since there are golfers who prefer a springy rather than stifffeel off the tee, there is still a need for materials that can achievebenefits from stretching without inducing crystallinity within thepolymer network. Golf balls of the present invention address and solvethis need.

SUMMARY OF THE INVENTION

Accordingly, a method of the invention produces a golf ball having atleast one springy rather than stiff thermoset layer by advantageouslystretching or elongating a thermoset composition while in a partial curestate. In one embodiment, the method of making a golf ball comprises:providing a subassembly; providing a thermoset polymer composition;partially curing the thermoset polymer composition; elongating thethermoset polymer composition while in a partial cure state; forming alayer about the subassembly comprising the thermoset polymercomposition; and further curing the thermoset polymer composition.

The thermoset polymer composition may comprise a rubber-basedcomposition comprising at least one of polybutadiene, ethylene propylenerubber (EPR), ethylene-propylene-diene rubber (EPDM), styrene-butadienerubber, butyl rubber, halobutyl rubber, polyurethane, polyurea,acrylonitrile butadiene rubber, polychloroprene, alkyl acrylate rubber,polyalkenamer, phenol formaldehyde, melamine formaldehyde, polyepoxide,polysiloxane, polyester, alkyd, polyisocyanurate, polycyanurate,polyacrylate, and combinations thereof.

In another embodiment, the method of making a golf ball may comprise:providing a subassembly; providing a moldable thermoset polymercomposition; elongating the thermoset polymer composition while in astate of partial cure; forming the thermoset composition into a layerabout the subassembly; and further curing the thermoset polymercomposition.

In a different embodiment, the method of the invention may comprise:providing a subassembly; providing a thermoset polymer composition;stepwise elongating the thermoset polymer composition by at least thesteps of: (i) stretching the thermoset polymer composition insubstantially one plane while the thermoset polymer composition is in apartial cure state and before forming the thermoset polymer compositioninto first and second half shells, and (ii) forming the thermosetpolymer composition into first and second half shells and elongating thethermoset polymer composition in three dimensions while the thermosetpolymer composition is in the partial cure state and before mating thefirst and second half shells about the subassembly; then mating thefirst and second half shells about the subassembly and forming astepwise-elongated thermoset layer.

The partial cure state may be characterized by a curing time less thanT90. In one embodiment, the partial cure state may be characterized by acuring time T60 or less. In another embodiment, the partial cure statemay be characterized by a curing time T40 or less.

The thermoset polymer composition may be elongated from 10% to 200%during the partial cure state. In one embodiment, the thermoset polymercomposition is elongated at least 50% during the partial cure state. Inanother embodiment, the thermoset polymer composition is elongated atleast 100% during the partial cure state. In yet another embodiment, thethermoset polymer composition is elongated at least 150% during thepartial cure state. In still another embodiment, the thermoset polymercomposition is elongated 200% or greater during the partial cure state.

In one embodiment, the layer comprises an outer core layer and thesubassembly is an inner core layer. In another embodiment, the layercomprises an inner cover layer and the subassembly is a core. In yetanother embodiment, the layer comprises an intermediate layer disposedbetween the subassembly and at least one cover layer.

In one embodiment of stepwise elongation, the step of elongating thethermoset polymer composition in three dimensions may follow forming thethermoset polymer composition into first and second half shells. Inanother embodiment of stepwise elongation, the step of elongating thethermoset polymer composition in three dimensions and the step offorming the thermoset polymer composition into first and second halfshells may occur simultaneously.

In some embodiments of stepwise elongation, the partial cure state canbe interrupted for a predetermined duration following stretching thethermoset polymer composition in substantially one plane and prior toelongating the thermoset polymer composition in three dimensions.Additionally or alternatively, in some embodiments, curing can beinterrupted for a predetermined duration while elongating the thermosetpolymer composition in three dimensions.

In one embodiment, the first and second half shells may be compressionmolded about the subassembly.

DETAILED DESCRIPTION

A method of the invention produces a golf ball having at least onespringy rather than stiff layer of a thermoset composition that iselongated or otherwise stretched while in a partial cure state.Elongating the thermoset composition during a state of partial curesubstantially reduces crystallinity from developing within the polymernetwork during stretching or elongation, thereby avoiding the stiffnesswhich results when a cured thermoset material is stretched.

Generally, partial cure is any state below T90 as measuredrheometrically. In this regard, T90 is conventionally determined as thetime, dependent on the reaction temperature, where the viscosity of thereaction mixture increases by 90% of the value it will attain in thefully cured material. In such a partially cured state, the material canbe elongated without full properties being developed until furthercuring time. Thus, in one embodiment, the partial cure state may becharacterized by a curing time less than T90. In another embodiment, thepartial cure state may be characterized by a curing time less than T70(the viscosity of the reaction mixture increases by less than 70% of thevalue it will attain in the fully cured material). In other embodiments,the partial cure state may be characterized by a curing time T60 or less(the viscosity of the reaction mixture increases by 60% or less of thevalue it will attain in the fully cured material), or characterized by acuring time less than T60 (the viscosity of the reaction mixtureincreases by less than 60% of the value it will attain in the fullycured material), or characterized by a curing time T40 or less (theviscosity of the reaction mixture increases by 40% or less of the valueit will attain in the fully cured material), or characterized by acuring time less than T40 (the viscosity of the reaction mixtureincreases by less than 40% of the value it will attain in the fullycured material).

A partial cure state may be achieved by controlling the cure agents,temperatures, pressures, and cure times employed in the cure. Forexample, in some embodiments, a process employing two cure agents, suchas two organic peroxides, with different cure temperature/half-lifeprofiles can allow an initial partial cure at a lower temperature andfurther curing at higher temperature after the thermoset polymercomposition has been elongated and molded.

In other embodiments, two different classes of cure agents, such assulfurs and peroxides, may be used to first provide a partial curebefore elongation, molding, and further curing. Additionally oralternatively, a thermoset polymer composition may be first partiallycured under lower pressure and/or temperature before being further curedwith higher pressure and/or temperature after being elongated in a mold.In some embodiments, a partial cure is obtained by interrupting a cureearly in its process once the thermoset polymer composition is partiallycured and lightly cross-linked, followed by elongating and molding thecomposition, prior to curing it further.

In one embodiment, a method of making a golf ball comprises: providing asubassembly; providing a thermoset polymer composition; partially curingthe thermoset polymer composition; elongating the thermoset polymercomposition while in a partial cure state; forming a layer about thesubassembly comprising the thermoset polymer composition; and furthercuring the thermoset polymer composition.

The thermoset polymer composition may comprise, for example, arubber-based composition comprising at least one of polybutadiene,ethylene propylene rubber (EPR), ethylene-propylene-diene rubber (EPDM),styrene-butadiene rubber, butyl rubber, halobutyl rubber, polyurethane,polyurea, acrylonitrile butadiene rubber, polychloroprene, alkylacrylate rubber, polyalkenamer, phenol formaldehyde, melamineformaldehyde, polyepoxide, polysiloxane, polyester, alkyd,polyisocyanurate, polycyanurate, polyacrylate, and combinations thereof.

The method of making a golf ball may alternatively comprise: providing asubassembly; providing a moldable thermoset polymer composition;elongating the thermoset polymer composition while in a state of partialcure; forming the thermoset composition into a layer about thesubassembly; and further curing the thermoset polymer composition.

In a different embodiment, the method of the invention of making a golfball may comprise: providing a subassembly; providing a thermosetpolymer composition; stepwise elongating the thermoset polymercomposition by at least the steps of: (i) stretching the thermosetpolymer composition in substantially one plane while the thermosetpolymer composition is in a partial cure state and before forming thethermoset polymer composition into first and second half shells, and(ii) forming the thermoset polymer composition into first and secondhalf shells and elongating the thermoset polymer composition in threedimensions while the thermoset polymer composition is in the partialcure state and before mating the first and second half shells about thesubassembly; then mating the first and second half shells about thesubassembly and forming a stepwise-elongated thermoset layer.

The thermoset polymer composition may be elongated from 10% to 200%during the partial cure state. In one embodiment, the thermoset polymercomposition is elongated at least 50% during the partial cure state. Inanother embodiment, the thermoset polymer composition is elongated atleast 100% during the partial cure state. In yet another embodiment, thethermoset polymer composition is elongated at least 150% during thepartial cure state. In still another embodiment, the thermoset polymercomposition is elongated 200% or greater during the partial cure state.

In one embodiment, the layer comprises an outer core layer and thesubassembly is an inner core layer. In another embodiment, the layercomprises an inner cover layer and the subassembly is a core. In yetanother embodiment, the layer comprises an intermediate layer disposedbetween the subassembly and at least one cover layer.

In one embodiment of stepwise elongation, the step of elongating thethermoset polymer composition in three dimensions follows forming thethermoset polymer composition into first and second half shells. Inanother embodiment, the step of elongating the thermoset polymercomposition in three dimensions and the step of forming the thermosetpolymer composition into first and second half shells occursimultaneously.

In some embodiments of stepwise elongation, the partial cure state canbe interrupted for a predetermined duration following stretching thethermoset polymer composition in substantially one plane and prior toelongating the thermoset polymer composition in three dimensions.Additionally or alternatively, in some embodiments, cure of thethermoset polymer composition can be interrupted for a predeterminedduration while elongating the thermoset polymer composition in threedimensions.

In one embodiment, the first and second half shells may be compressionmolded about the subassembly.

Golf balls made by a method of the invention may comprise a core, acover and, optionally, at least one intermediate layer disposedconcentrically adjacent to the core between the core and the cover. Thecore may be single or a multi-layered and the cover may also compriseone or more layers. At least one of portion of the golf ball, i.e.,core, cover, optional intermediate layer, coating layer and/or atie-layer comprises at least one layer of elongated material asdescribed herein.

Meanwhile, in a golf ball of the invention incorporating an elongatedthermoset layer, an overall golf ball coefficient of restitution (CoR)may be targeted by coordinating the CoR of each subassembly of the golfball. In this regard, a subassembly of any layer refers to that layerplus all the inner layers disposed within/underneath that layer. In thisfashion, the center, the intermediate layers and the cover layer may beconstructed to have different CoR's. And it is envisioned that a golfball of the invention may be formulated and constructed to have anydesired overall golf ball CoR.

The CoR is a measure of the resilience of a golf ball. A relatively highgolf ball CoR allows the golf ball to reach high velocity when struck bya golf club. Thus, the ball tends to travel a greater distance which isparticularly important for driver shots off the tee. At the same time,it is often desirable that a golf ball exhibit a soft and comfortablefeel. Players can then experience a better sense of control and naturalfeeling when making the shot. In this regard, the coefficient ofrestitution or CoR of a golf ball or golf ball subassembly (for example,a golf ball core) is the ratio of the relative velocity of an elasticsphere after direct impact to that before impact. CoR can therefore varyfrom 0 to 1, with 1 being equivalent to a perfectly or completelyelastic collision and 0 being equivalent to a perfectly or completelyinelastic collision. The CoR is determined according to a knownprocedure, wherein the golf ball or golf ball subassembly is fired froman air cannon at two given velocities and a velocity of 125 ft/s is usedfor the calculations. Ballistic light screens are located between theair cannon and steel plate at a fixed distance to measure ball velocity.As the ball travels toward the steel plate, it activates each lightscreen and the ball's time period at each light screen is measured. Thisprovides an incoming transit time period which is inversely proportionalto the ball's incoming velocity. The ball makes impact with the steelplate and rebounds so it passes again through the light screens. As therebounding ball activates each light screen, the ball's time period ateach screen is measured. This provides an outgoing transit time periodwhich is inversely proportional to the ball's outgoing velocity. The CoRis then calculated as the ratio of the ball's outgoing transit timeperiod to the ball's incoming transit time period(CoR=V_(out)/V_(in)=T_(in)/T_(out)).

Thus, in one non-limiting example, a golf ball of the inventioncomprises a first subassembly, surrounded by a second subassembly whichincludes a layer of elongated thermoset polymer composition. The firstsubassembly has a first coefficient of restitution that is less than asecond coefficient of restitution of the second subassembly. Meanwhile,the golf ball as a whole, which also includes a cover disposed about thesecond subassembly, has a ball coefficient of restitution that isgreater than the first coefficient of restitution and less than thesecond coefficient of restitution. The first subassembly can be, forexample, a single core, or a dual core, or a core surrounded by anintermediate layer, or even a core, intermediate layer and inner coverlayer, combined. In turn, the layer of elongated thermoset polymercomposition can be any golf ball layer as desired to achieve or targetplaying characteristics.

A golf ball of the invention may otherwise be constructed of any knownnumber of other layers formed from conventional golf ball materials andhaving any known diameter and/or thickness, hardness, compression and/orother golf ball properties, which, when coordinated with the at leastone layer of thermoset polymer composition elongated while in a partialcure state, may target particular desired playing characteristics.

For example, in one particular embodiment of a golf ball of theinvention, the innermost golf ball layer of a golf ball of the inventionmay be a conventional rubber-containing inner core, wherein the baserubber may be selected from polybutadiene rubber, polyisoprene rubber,natural rubber, ethylene-propylene rubber, ethylene-propylene dienerubber, styrene-butadiene rubber, and combinations of two or morethereof. A preferred base rubber is polybutadiene. Another preferredbase rubber is polybutadiene optionally mixed with one or moreelastomers selected from polyisoprene rubber, natural rubber, ethylenepropylene rubber, ethylene propylene diene rubber, styrene-butadienerubber, polystyrene elastomers, polyethylene elastomers, polyurethaneelastomers, polyurea elastomers, metallocene-catalyzed elastomers, andplastomers.

Suitable curing processes include, for example, peroxide curing, sulfurcuring, radiation, and combinations thereof. In one embodiment, the baserubber is peroxide cured. Organic peroxides suitable as free-radicalinitiators include, for example, dicumyl peroxide;n-butyl-4,4-di(t-butylperoxy) valerate;1,1-di(t-butylperoxy)3,3,5-trimethylcyclohexane;2,5-dimethyl-2,5-di(t-butylperoxy) hexane; di-t-butyl peroxide;di-t-amyl peroxide; t-butyl peroxide; t-butyl cumyl peroxide;2,5-dimethyl-2,5-di(t-butylperoxy)hexyne-3;di(2-t-butyl-peroxyisopropyl)benzene; dilauroyl peroxide; dibenzoylperoxide; t-butyl hydroperoxide; and combinations thereof. Peroxidefree-radical initiators are generally present in the rubber compositionsin an amount within the range of 0.05 to 15 parts, preferably 0.1 to 10parts, and more preferably 0.25 to 6 parts by weight per 100 parts ofthe base rubber. Cross-linking agents are used to cross-link at least aportion of the polymer chains in the composition. Suitable cross-linkingagents include, for example, metal salts of unsaturated carboxylic acidshaving from 3 to 8 carbon atoms; unsaturated vinyl compounds andpolyfunctional monomers (e.g., trimethylolpropane trimethacrylate);phenylene bismaleimide; and combinations thereof. Particularly suitablemetal salts include, for example, one or more metal salts of acrylates,diacrylates, methacrylates, and dimethacrylates, wherein the metal isselected from magnesium, calcium, zinc, aluminum, lithium, and nickel.In a particular embodiment, the cross-linking agent is selected fromzinc salts of acrylates, diacrylates, methacrylates, anddimethacrylates. When the cross-linking agent is zinc diacrylate and/orzinc dimethacrylate, the agent typically is included in the rubbercomposition in an amount within the range of 1 to 60 parts, preferably 5to 50 parts, and more preferably 10 to 40 parts, by weight per 100 partsof the base rubber.

In a preferred embodiment, the cross-linking agent used in the rubbercomposition of the core and epoxy composition of the intermediate layerand/or cover layer is zinc diacrylate (“ZDA”). Adding the ZDA curingagent to the rubber composition makes the core harder and improves theresiliency/CoR of the ball. Adding the same ZDA curing agent epoxycomposition makes the intermediate and cover layers harder and morerigid. As a result, the overall durability, toughness, and impactstrength of the ball is improved.

Sulfur and sulfur-based curing agents with optional accelerators may beused in combination with or in replacement of the peroxide initiators tocross-link the base rubber. High energy radiation sources capable ofgenerating free-radicals may also be used to cross-link the base rubber.Suitable examples of such radiation sources include, for example,electron beams, ultra-violet radiation, gamma radiation, X-rayradiation, infrared radiation, heat, and combinations thereof.

The rubber compositions may also contain “soft and fast” agents such asa halogenated organosulfur, organic disulfide, or inorganic disulfidecompound. Particularly suitable halogenated organosulfur compoundsinclude, but are not limited to, halogenated thiophenols. Preferredorganic sulfur compounds include, but not limited to,pentachlorothiophenol (“PCTP”) and a salt of PCTP. A preferred salt ofPCTP is ZnPCTP. A suitable PCTP is sold by the Struktol Company (Stow,Ohio) under the tradename, A 95. ZnPCTP is commercially available fromeChinaChem Inc. (San Francisco, Calif.). These compounds also mayfunction as cis-to-trans catalysts to convert some cis-1,4 bonds in thepolybutadiene to trans-1,4 bonds. Peroxide free-radical initiators aregenerally present in the rubber compositions in an amount within therange of 0.05 to 10 parts and preferably 0.1 to 5 parts. Antioxidantsalso may be added to the rubber compositions to prevent the breakdown ofthe elastomers. Other ingredients such as accelerators (for example,tetra methylthiurams), processing aids, processing oils, dyes andpigments, wetting agents, surfactants, plasticizers, as well as otheradditives known in the art may be added to the composition. Generally,the fillers and other additives are present in the rubber composition inan amount within the range of 1 to 70 parts by weight per 100 parts ofthe base rubber. The core may be formed by mixing and forming the rubbercomposition using conventional techniques. Of course, embodiments arealso envisioned wherein outer layers comprise such rubber-basedcompositions

However, core layers, intermediate/casing layers, and cover layers mayadditionally or alternatively be formed from other conventionalmaterials such as an ionomeric material including ionomeric polymers,preferably highly-neutralized ionomers (HNP). In another embodiment, theintermediate layer of the golf ball is formed from an HNP material or ablend of HNP materials. The acid moieties of the HNP's, typicallyethylene-based ionomers, are preferably neutralized greater than about70%, more preferably greater than about 90%, and most preferably atleast about 100%. The HNP's can be also be blended with a second polymercomponent, which, if containing an acid group, may also be neutralized.The second polymer component, which may be partially or fullyneutralized, preferably comprises ionomeric copolymers and terpolymers,ionomer precursors, thermoplastics, polyamides, polycarbonates,polyesters, polyurethanes, polyureas, polyurethane/urea hybrids,thermoplastic elastomers, polybutadiene rubber, balata,metallocene-catalyzed polymers (grafted and non-grafted), single-sitepolymers, high-crystalline acid polymers, cationic ionomers, and thelike. HNP polymers typically have a material hardness of between about20 and about 80 Shore D, and a flexural modulus of between about 3,000psi and about 200,000 psi.

Non-limiting examples of suitable ionomers include partially neutralizedionomers, blends of two or more partially neutralized ionomers, highlyneutralized ionomers, blends of two or more highly neutralized ionomers,and blends of one or more partially neutralized ionomers with one ormore highly neutralized ionomers. Methods of preparing ionomers are wellknown, and are disclosed, for example, in U.S. Pat. No. 3,264,272, theentire disclosure of which is hereby incorporated herein by reference.The acid copolymer can be a direct copolymer wherein the polymer ispolymerized by adding all monomers simultaneously, as disclosed, forexample, in U.S. Pat. No. 4,351,931, the entire disclosure of which ishereby incorporated herein by reference. Alternatively, the acidcopolymer can be a graft copolymer wherein a monomer is grafted onto anexisting polymer, as disclosed, for example, in U.S. Patent ApplicationPublication No. 2002/0013413, the entire disclosure of which is herebyincorporated herein by reference.

Examples of suitable partially neutralized acid polymers include, butare not limited to, Surlyn® ionomers, commercially available from E. I.du Pont de Nemours and Company; AClyn® ionomers, commercially availablefrom Honeywell International Inc.; and Iotek® ionomers, commerciallyavailable from Exxon Mobil Chemical Company. Some suitable examples ofhighly neutralized ionomers (HNP) are DuPont® HPF 1000 and DuPont® HPF2000, ionomeric materials commercially available from E. I. du Pont deNemours and Company. In some embodiments, very low modulus ionomer-(“VLMI-”) type ethylene-acid polymers are particularly suitable forforming the HNP, such as Surlyn® 6320, Surlyn® 8120, Surlyn® 8320, andSurlyn® 9320, commercially available from E. I. du Pont de Nemours andCompany.

It is meanwhile envisioned that in some embodiments/golf ballconstructions, it may be beneficial to also include at least one layerformed from or blended with a conventional isocyante-based material. Thefollowing conventional compositions as known in the art may beincorporated to achieve particular desired golf ball characteristics:

(1) Polyurethanes, such as those prepared from polyols and diisocyanatesor polyisocyanates and/or their prepolymers, and those disclosed in U.S.Pat. Nos. 5,334,673 and 6,506,851;

(2) Polyureas, such as those disclosed in U.S. Pat. Nos. 5,484,870 and6,835,794; and

(3) Polyurethane/urea hybrids, blends or copolymers comprising urethaneand urea segments such as those disclosed in U.S. Pat. No. 8,506,424.

Suitable polyurethane compositions comprise a reaction product of atleast one polyisocyanate and at least one curing agent. The curing agentcan include, for example, one or more polyols. The polyisocyanate can becombined with one or more polyols to form a prepolymer, which is thencombined with the at least one curing agent. Thus, the polyols describedherein are suitable for use in one or both components of thepolyurethane material, i.e., as part of a prepolymer and in the curingagent. Suitable polyurethanes are described in U.S. Pat. No. 7,331,878,which is incorporated herein in its entirety by reference.

In general, polyurea compositions contain urea linkages formed byreacting an isocyanate group (—N═C═O) with an amine group (NH or NH₂).The chain length of the polyurea prepolymer is extended by reacting theprepolymer with an amine curing agent. The resulting polyurea haselastomeric properties, because of its “hard” and “soft” segments, whichare covalently bonded together. The soft, amorphous, low-melting pointsegments, which are formed from the polyamines, are relatively flexibleand mobile, while the hard, high-melting point segments, which areformed from the isocyanate and chain extenders, are relatively stiff andimmobile. The phase separation of the hard and soft segments providesthe polyurea with its elastomeric resiliency. The polyurea compositioncontains urea linkages having the following general structure:

where x is the chain length, i.e., about 1 or greater, and R and R₁ arestraight chain or branched hydrocarbon chains having about 1 to about 20carbon atoms.

A polyurea/polyurethane hybrid composition is produced when the polyureaprepolymer (as described above) is chain-extended using ahydroxyl-terminated curing agent. Any excess isocyanate groups in theprepolymer will react with the hydroxyl groups in the curing agent andcreate urethane linkages. That is, a polyurea/polyurethane hybridcomposition is produced.

In a preferred embodiment, a pure polyurea composition, as describedabove, is prepared. That is, the composition contains only urealinkages. An amine-terminated curing agent is used in the reaction toproduce the pure polyurea composition. However, it should be understoodthat a polyurea/polyurethane hybrid composition also may be prepared inaccordance with this invention as discussed above. Such a hybridcomposition can be formed if the polyurea prepolymer is cured with ahydroxyl-terminated curing agent. Any excess isocyanate in the polyureaprepolymer reacts with the hydroxyl groups in the curing agent and formsurethane linkages. The resulting polyurea/polyurethane hybridcomposition contains both urea and urethane linkages. The generalstructure of a urethane linkage is shown below:

where x is the chain length, i.e., about 1 or greater, and R and R₁ arestraight chain or branched hydrocarbon chains having about 1 to about 20carbon atoms.

There are two basic techniques that can be used to make the polyurea andpolyurea/urethane compositions of this invention: a) one-shot technique,and b) prepolymer technique. In the one-shot technique, the isocyanateblend, polyamine, and hydroxyl and/or amine-terminated curing agent arereacted in one step. On the other hand, the prepolymer techniqueinvolves a first reaction between the isocyanate blend and polyamine toproduce a polyurea prepolymer, and a subsequent reaction between theprepolymer and hydroxyl and/or amine-terminated curing agent. As aresult of the reaction between the isocyanate and polyamine compounds,there will be some unreacted NCO groups in the polyurea prepolymer. Theprepolymer should have less than 14% unreacted NCO groups. Preferably,the prepolymer has no greater than 8.5% unreacted NCO groups, morepreferably from 2.5% to 8%, and most preferably from 5.0% to 8.0%unreacted NCO groups. As the weight percent of unreacted isocyanategroups increases, the hardness of the composition also generallyincreases.

Either the one-shot or prepolymer method may be employed to produce thepolyurea and polyurea/urethane compositions of the invention; however,the prepolymer technique is preferred because it provides better controlof the chemical reaction. The prepolymer method provides a morehomogeneous mixture resulting in a more consistent polymer composition.The one-shot method results in a mixture that is inhomogeneous (morerandom) and affords the manufacturer less control over the molecularstructure of the resultant composition.

In the casting process, the polyurea and polyurea/urethane compositionscan be formed by chain-extending the polyurea prepolymer with a singlecuring agent or blend of curing agents as described further below. Thecompositions of the present invention may be selected from among bothcastable thermoplastic and thermoset materials. Thermoplastic polyureacompositions are typically formed by reacting the isocyanate blend andpolyamines at a 1:1 stoichiometric ratio. Thermoset compositions, on theother hand, are cross-linked polymers and are typically produced fromthe reaction of the isocyanate blend and polyamines at normally a 1.05:1stoichiometric ratio. In general, thermoset polyurea compositions areeasier to prepare than thermoplastic polyureas.

The polyurea prepolymer can be chain-extended by reacting it with asingle curing agent or blend of curing agents (chain-extenders). Ingeneral, the prepolymer can be reacted with hydroxyl-terminated curingagents, amine-terminated curing agents, or mixtures thereof. The curingagents extend the chain length of the prepolymer and build-up itsmolecular weight. Normally, the prepolymer and curing agent are mixed sothe isocyanate groups and hydroxyl or amine groups are mixed at a1.05:1.00 stoichiometric ratio.

A catalyst may be employed to promote the reaction between theisocyanate and polyamine compounds for producing the prepolymer orbetween prepolymer and curing agent during the chain-extending step.Preferably, the catalyst is added to the reactants before producing theprepolymer. Suitable catalysts include, but are not limited to, bismuthcatalyst; zinc octoate; stannous octoate; tin catalysts such asbis-butyltin dilaurate, bis-butyltin diacetate, stannous octoate; tin(II) chloride, tin (IV) chloride, bis-butyltin dimethoxide,dimethyl-bis[1-oxonedecyl)oxy]stannane, di-n-octyltin bis-isooctylmercaptoacetate; amine catalysts such as triethylenediamine,triethylamine, and tributylamine; organic acids such as oleic acid andacetic acid; delayed catalysts; and mixtures thereof. The catalyst ispreferably added in an amount sufficient to catalyze the reaction of thecomponents in the reactive mixture. In one embodiment, the catalyst ispresent in an amount from about 0.001 percent to about 1 percent, andpreferably 0.1 to 0.5 percent, by weight of the composition.

The hydroxyl chain-extending (curing) agents are preferably selectedfrom the group consisting of ethylene glycol; diethylene glycol;polyethylene glycol; propylene glycol; 2-methyl-1,3-propanediol;2-methyl-1,4-butanediol; monoethanolamine; diethanolamine;triethanolamine; monoisopropanolamine; diisopropanolamine; dipropyleneglycol; polypropylene glycol; 1,2-butanediol; 1,3-butanediol;1,4-butanediol; 2,3-butanediol; 2,3-dimethyl-2,3-butanediol;trimethylolpropane; cyclohexyldimethylol; triisopropanolamine;N,N,N′,N′-tetra-(2-hydroxypropyl)-ethylene diamine; diethylene glycolbis-(aminopropyl) ether; 1,5-pentanediol; 1,6-hexanediol;1,3-bis-(2-hydroxyethoxy)cyclohexane; 1,4-cyclohexyldimethylol;1,3-bis-[2-(2-hydroxyethoxy) ethoxy]cyclohexane;1,3-bis-{2-[2-(2-hydroxyethoxy) ethoxy]ethoxy}cyclohexane;trimethylolpropane; polytetramethylene ether glycol (PTMEG), preferablyhaving a molecular weight from about 250 to about 3900; and mixturesthereof.

Suitable amine chain-extending (curing) agents that can be used inchain-extending the polyurea prepolymer of this invention include, butare not limited to, unsaturated diamines such as4,4′-diamino-diphenylmethane (i.e., 4,4′-methylene-dianiline or “MDA”),m-phenylenediamine, p-phenylenediamine, 1,2- or1,4-bis(sec-butylamino)benzene, 3,5-diethyl-(2,4- or 2,6-)toluenediamine or “DETDA”, 3,5-dimethylthio-(2,4- or2,6-)toluenediamine, 3,5-diethylthio-(2,4- or 2,6-)toluenediamine,3,3′-dimethyl-4,4′-diamino-diphenylmethane,3,3′-diethyl-5,5′-dimethyl4,4′-diamino-diphenylmethane (i.e.,4,4′-methylene-bis(2-ethyl-6-methyl-benezeneamine)),3,3′-dichloro-4,4′-diamino-diphenylmethane (i.e.,4,4′-methylene-bis(2-chloroaniline) or “MOCA”),3,3′,5,5′-tetraethyl-4,4′-diamino-diphenylmethane (i.e.,4,4′-methylene-bis(2,6-diethylaniline),2,2′-dichloro-3,3′,5,5′-tetraethyl-4,4′-diamino-diphenylmethane (i.e.,4,4′-methylene-bis(3-chloro-2,6-diethyleneaniline) or “MCDEA”),3,3′-diethyl-5,5′-dichloro-4,4′-diamino-diphenylmethane, or “MDEA”),3,3′-dichloro-2,2′,6,6′-tetraethyl-4,4′-diamino-diphenylmethane,3,3′-dichloro-4,4′-diamino-diphenylmethane,4,4′-methylene-bis(2,3-dichloroaniline) (i.e.,2,2′,3,3′-tetrachloro-4,4′-diamino-diphenylmethane or “MDCA”),4,4′-bis(sec-butylamino)-diphenylmethane,N,N′-dialkylamino-diphenylmethane,trimethyleneglycol-di(p-aminobenzoate),polyethyleneglycol-di(p-aminobenzoate),polytetramethyleneglycol-di(p-aminobenzoate); saturated diamines such asethylene diamine, 1,3-propylene diamine, 2-methyl-pentamethylenediamine, hexamethylene diamine, 2,2,4- and 2,4,4-trimethyl-1,6-hexanediamine, imino-bis(propylamine), imido-bis(propylamine),methylimino-bis(propylamine) (i.e.,N-(3-aminopropyl)-N-methyl-1,3-propanediamine),1,4-bis(3-aminopropoxy)butane (i.e.,3,3′-[1,4-butanediylbis-(oxy)bis]-1-propanamine),diethyleneglycol-bis(propylamine) (i.e.,diethyleneglycol-di(aminopropyl)ether),4,7,10-trioxatridecane-1,13-diamine, 1-methyl-2,6-diamino-cyclohexane,1,4-diamino-cyclohexane, poly(oxyethylene-oxypropylene)diamines, 1,3- or1,4-bis(methylamino)-cyclohexane, isophorone diamine, 1,2- or1,4-bis(sec-butylamino)-cyclohexane, N,N′-diisopropyl-isophoronediamine, 4,4′-diamino-dicyclohexylmethane,3,3′-dimethyl-4,4′-diamino-dicyclohexylmethane,3,3′-dichloro-4,4′-diamino-dicyclohexylmethane,N,N′-dialkylamino-dicyclohexylmethane, polyoxyethylene diamines,3,3′-diethyl-5,5′-dimethyl-4,4′-diamino-dicyclohexylmethane,polyoxypropylene diamines,3,3′-diethyl-5,5′-dichloro-4,4′-diamino-dicyclohexylmethane,polytetramethylene ether diamines,3,3′,5,5′-tetraethyl-4,4′-diamino-dicyclohexylmethane (i.e.,4,4′-methylene-bis(2,6-diethylaminocyclohexane)),3,3′-dichloro-4,4′-diamino-dicyclohexylmethane,2,2′-dichloro-3,3′,5,5′-tetraethyl-4,4′-diamino-dicyclohexylmethane,(ethylene oxide)-capped polyoxypropylene ether diamines,2,2′,3,3′-tetrachloro-4,4′-diamino-dicyclohexylmethane,4,4′-bis(sec-butylamino)-dicyclohexylmethane; triamines such asdiethylene triamine, dipropylene triamine, (propylene oxide)-basedtriamines (i.e., polyoxypropylene triamines),N-(2-aminoethyl)-1,3-propylenediamine (i.e., N₃-amine), glycerin-basedtriamines, (all saturated); tetramines such asN,N′-bis(3-aminopropyl)ethylene diamine (i.e., N₄-amine) (bothsaturated), triethylene tetramine; and other polyamines such astetraethylene pentamine (also saturated). One suitable amine-terminatedchain-extending agent is Ethacure 300™ (dimethylthiotoluenediamine or amixture of 2,6-diamino-3,5-dimethylthiotoluene and2,4-diamino-3,5-dimethylthiotoluene.) The amine curing agents used aschain extenders normally have a cyclic structure and a low molecularweight (250 or less).

When the polyurea prepolymer is reacted with amine-terminated curingagents during the chain-extending step, as described above, theresulting composition is essentially a pure polyurea composition. On theother hand, when the polyurea prepolymer is reacted with ahydroxyl-terminated curing agent during the chain-extending step, anyexcess isocyanate groups in the prepolymer will react with the hydroxylgroups in the curing agent and create urethane linkages to form apolyurea/urethane hybrid.

This chain-extending step, which occurs when the polyurea prepolymer isreacted with hydroxyl curing agents, amine curing agents, or mixturesthereof, builds-up the molecular weight and extends the chain length ofthe prepolymer. When the polyurea prepolymer is reacted with aminecuring agents, a polyurea composition having urea linkages is produced.When the polyurea prepolymer is reacted with hydroxyl curing agents, apolyurea/urethane hybrid composition containing both urea and urethanelinkages is produced. The polyurea/urethane hybrid composition isdistinct from the pure polyurea composition. The concentration of ureaand urethane linkages in the hybrid composition may vary. In general,the hybrid composition may contain a mixture of about 10 to 90% urea andabout 90 to 10% urethane linkages. The resulting polyurea orpolyurea/urethane hybrid composition has elastomeric properties based onphase separation of the soft and hard segments. The soft segments, whichare formed from the polyamine reactants, are generally flexible andmobile, while the hard segments, which are formed from the isocyanatesand chain extenders, are generally stiff and immobile.

In an alternative embodiment, the cover layer may comprise aconventional polyurethane or polyurethane/urea hybrid composition. Ingeneral, polyurethane compositions contain urethane linkages formed byreacting an isocyanate group (—N═C═O) with a hydroxyl group (OH). Thepolyurethanes are produced by the reaction of a multi-functionalisocyanate (NCO—R—NCO) with a long-chain polyol having terminal hydroxylgroups (OH—OH) in the presence of a catalyst and other additives. Thechain length of the polyurethane prepolymer is extended by reacting itwith short-chain diols (OH—R′—OH). The resulting polyurethane haselastomeric properties because of its “hard” and “soft” segments, whichare covalently bonded together. This phase separation occurs because themainly non-polar, low melting soft segments are incompatible with thepolar, high melting hard segments. The hard segments, which are formedby the reaction of the diisocyanate and low molecular weightchain-extending diol, are relatively stiff and immobile. The softsegments, which are formed by the reaction of the diisocyanate and longchain diol, are relatively flexible and mobile. Because the hardsegments are covalently coupled to the soft segments, they inhibitplastic flow of the polymer chains, thus creating elastomericresiliency.

Suitable isocyanate compounds that can be used to prepare thepolyurethane or polyurethane/urea hybrid material are described above.These isocyanate compounds are able to react with the hydroxyl or aminecompounds and form a durable and tough polymer having a high meltingpoint. The resulting polyurethane generally has good mechanical strengthand cut/shear-resistance. In addition, the polyurethane composition hasgood light and thermal-stability.

When forming a polyurethane prepolymer, any suitable polyol may bereacted with the above-described isocyanate blends in accordance withthis invention. Exemplary polyols include, but are not limited to,polyether polyols, hydroxy-terminated polybutadiene (includingpartially/fully hydrogenated derivatives), polyester polyols,polycaprolactone polyols, and polycarbonate polyols. In one preferredembodiment, the polyol includes polyether polyol. Examples include, butare not limited to, polytetramethylene ether glycol (PTMEG),polyethylene propylene glycol, polyoxypropylene glycol, and mixturesthereof. The hydrocarbon chain can have saturated or unsaturated bondsand substituted or unsubstituted aromatic and cyclic groups. Preferably,the polyol of the present invention includes PTMEG.

In another embodiment, polyester polyols are included in thepolyurethane material. Suitable polyester polyols include, but are notlimited to, polyethylene adipate glycol; polybutylene adipate glycol;polyethylene propylene adipate glycol; o-phthalate-1,6-hexanediol;poly(hexamethylene adipate) glycol; and mixtures thereof. Thehydrocarbon chain can have saturated or unsaturated bonds, orsubstituted or unsubstituted aromatic and cyclic groups. In stillanother embodiment, polycaprolactone polyols are included in thematerials of the invention. Suitable polycaprolactone polyols include,but are not limited to: 1,6-hexanediol-initiated polycaprolactone,diethylene glycol initiated polycaprolactone, trimethylol propaneinitiated polycaprolactone, neopentyl glycol initiated polycaprolactone,1,4-butanediol-initiated polycaprolactone, and mixtures thereof. Thehydrocarbon chain can have saturated or unsaturated bonds, orsubstituted or unsubstituted aromatic and cyclic groups. In yet anotherembodiment, polycarbonate polyols are included in the polyurethanematerial of the invention. Suitable polycarbonates include, but are notlimited to, polyphthalate carbonate and poly(hexamethylene carbonate)glycol. The hydrocarbon chain can have saturated or unsaturated bonds,or substituted or unsubstituted aromatic and cyclic groups. In oneembodiment, the molecular weight of the polyol is from about 200 toabout 4000.

In a manner similar to making the above-described polyurea compositions,there are two basic techniques that can be used to make the polyurethanecompositions of this invention: a) one-shot technique, and b) prepolymertechnique. In the one-shot technique, the isocyanate blend, polyol, andhydroxyl-terminated and/or amine-terminated chain-extender (curingagent) are reacted in one step. On the other hand, the prepolymertechnique involves a first reaction between the isocyanate blend andpolyol compounds to produce a polyurethane prepolymer, and a subsequentreaction between the prepolymer and hydroxyl-terminated and/oramine-terminated chain-extender. As a result of the reaction between theisocyanate and polyol compounds, there will be some unreacted NCO groupsin the polyurethane prepolymer. The prepolymer should have less than 14%unreacted NCO groups. Preferably, the prepolymer has no greater than8.5% unreacted NCO groups, more preferably from 2.5% to 8%, and mostpreferably from 5.0% to 8.0% unreacted NCO groups. As the weight percentof unreacted isocyanate groups increases, the hardness of thecomposition also generally increases.

Either the one-shot or prepolymer method may be employed to produce thepolyurethane compositions of the invention. In one embodiment, theone-shot method is used, wherein the isocyanate compound is added to areaction vessel and then a curative mixture comprising the polyol andcuring agent is added to the reaction vessel. The components are mixedtogether so that the molar ratio of isocyanate groups to hydroxyl groupsis in the range of about 1.01:1.00 to about 1.10:1.00. Preferably, themolar ratio is greater than or equal to 1.05:1.00. For example, themolar ratio can be in the range of 1.05:1.00 to 1.10:1.00. In a secondembodiment, the prepolymer method is used. In general, the prepolymertechnique is preferred because it provides better control of thechemical reaction. The prepolymer method provides a more homogeneousmixture resulting in a more consistent polymer composition. The one-shotmethod results in a mixture that is inhomogeneous (more random) andaffords the manufacturer less control over the molecular structure ofthe resultant composition.

The polyurethane compositions can be formed by chain-extending thepolyurethane prepolymer with a single curing agent (chain-extender) orblend of curing agents (chain-extenders) as described further below. Thecompositions of the present invention may be selected from among bothcastable thermoplastic and thermoset polyurethanes. Thermoplasticpolyurethane compositions are typically formed by reacting theisocyanate blend and polyols at a 1:1 stoichiometric ratio. Thermosetcompositions, on the other hand, are cross-linked polymers and aretypically produced from the reaction of the isocyanate blend and polyolsat normally a 1.05:1 stoichiometric ratio. In general, thermosetpolyurethane compositions are easier to prepare than thermoplasticpolyurethanes.

As discussed above, the polyurethane prepolymer can be chain-extended byreacting it with a single chain-extender or blend of chain-extenders. Ingeneral, the prepolymer can be reacted with hydroxyl-terminated curingagents, amine-terminated curing agents, and mixtures thereof. The curingagents extend the chain length of the prepolymer and build-up itsmolecular weight. Normally, the prepolymer and curing agent are mixed sothe isocyanate groups and hydroxyl or amine groups are mixed at a1.05:1.00 stoichiometric ratio.

A catalyst may be employed to promote the reaction between theisocyanate and polyol compounds for producing the polyurethaneprepolymer or between the polyurethane prepolymer and chain-extenderduring the chain-extending step. Preferably, the catalyst is added tothe reactants before producing the polyurethane prepolymer. Suitablecatalysts include, but are not limited to, the catalysts described abovefor making the polyurea prepolymer. The catalyst is preferably added inan amount sufficient to catalyze the reaction of the components in thereactive mixture. In one embodiment, the catalyst is present in anamount from about 0.001 percent to about 1 percent, and preferably 0.1to 0.5 percent, by weight of the composition.

Suitable hydroxyl chain-extending (curing) agents and aminechain-extending (curing) agents include, but are not limited to, thecuring agents described above for making the polyurea andpolyurea/urethane hybrid compositions. When the polyurethane prepolymeris reacted with hydroxyl-terminated curing agents during thechain-extending step, as described above, the resulting polyurethanecomposition contains urethane linkages. On the other hand, when thepolyurethane prepolymer is reacted with amine-terminated curing agentsduring the chain-extending step, any excess isocyanate groups in theprepolymer will react with the amine groups in the curing agent. Theresulting polyurethane composition contains urethane and urea linkagesand may be referred to as a polyurethane/urea hybrid. The concentrationof urethane and urea linkages in the hybrid composition may vary. Ingeneral, the hybrid composition may contain a mixture of about 10 to 90%urethane and about 90 to 10% urea linkages.

Those layers of golf balls of the invention comprising conventionalthermoplastic or thermoset materials may be formed using a variety ofconventional application techniques such as compression molding, flipmolding, injection molding, retractable pin injection molding, reactioninjection molding (RIM), liquid injection molding (LIM), casting, vacuumforming, powder coating, flow coating, spin coating, dipping, spraying,and the like. Conventionally, compression molding and injection moldingare applied to thermoplastic materials, whereas RIM, liquid injectionmolding, and casting are employed on thermoset materials. These andother manufacture methods are disclosed in U.S. Pat. Nos. 6,207,784 and5,484,870, the disclosures of which are incorporated herein by referencein their entireties.

A method of injection molding using a split vent pin can be found inU.S. Pat. No. 6,877,974, filed Dec. 22, 2000, entitled “Split Vent Pinfor Injection Molding.” Examples of retractable pin injection moldingmay be found in U.S. Pat. Nos. 6,129,881; 6,235,230; and 6,379,138.These molding references are incorporated in their entirety by referenceherein. In addition, a chilled chamber, i.e., a cooling jacket, such asthe one disclosed in U.S. Pat. No. 6,936,205, filed Nov. 22, 2000,entitled “Method of Making Golf Balls” may be used to cool thecompositions of the invention when casting, which also allows for ahigher loading of catalyst into the system.

Conventionally, compression molding and injection molding are applied tothermoplastic materials, whereas RIM, liquid injection molding, andcasting are employed on thermoset materials. These and other manufacturemethods are disclosed in U.S. Pat. Nos. 6,207,784 and 5,484,870, thedisclosures of which are incorporated herein by reference in theirentirety.

Castable reactive liquid polyurethanes and polyurea materials may beapplied over the inner ball using a variety of application techniquessuch as casting, injection molding spraying, compression molding,dipping, spin coating, or flow coating methods that are well known inthe art. In one embodiment, the castable reactive polyurethanes andpolyurea material is formed over the core using a combination of castingand compression molding. Conventionally, compression molding andinjection molding are applied to thermoplastic cover materials, whereasRIM, liquid injection molding, and casting are employed on thermosetcover materials.

U.S. Pat. No. 5,733,428, the entire disclosure of which is herebyincorporated by reference, discloses a method for forming a polyurethanecover on a golf ball core. Because this method relates to the use ofboth casting thermosetting and thermoplastic material as the golf ballcover, wherein the cover is formed around the core by mixing andintroducing the material in mold halves, the polyurea compositions mayalso be used employing the same casting process.

For example, once a polyurea composition is mixed, an exothermicreaction commences and continues until the material is solidified aroundthe core. It is important that the viscosity be measured over time, sothat the subsequent steps of filling each mold half, introducing thecore into one half and closing the mold can be properly timed foraccomplishing centering of the core cover halves fusion and achievingoverall uniformity. A suitable viscosity range of the curing urea mixfor introducing cores into the mold halves is determined to beapproximately between about 2,000 cP and about 30,000 cP, or within arange of about 8,000 cP to about 15,000 cP.

To start the cover formation, mixing of the prepolymer and curative isaccomplished in a motorized mixer inside a mixing head by feedingthrough lines metered amounts of curative and prepolymer. Top preheatedmold halves are filled and placed in fixture units using centering pinsmoving into apertures in each mold. At a later time, the cavity of abottom mold half, or the cavities of a series of bottom mold halves, isfilled with similar mixture amounts as used for the top mold halves.After the reacting materials have resided in top mold halves for about40 to about 100 seconds, preferably for about 70 to about 80 seconds, acore is lowered at a controlled speed into the gelling reacting mixture.

A ball cup holds the shell through reduced pressure (or partial vacuum).Upon location of the core in the halves of the mold after gelling forabout 4 to about 12 seconds, the vacuum is released allowing the core tobe released. In one embodiment, the vacuum is released allowing the coreto be released after about 5 seconds to 10 seconds. The mold halves,with core and solidified cover half thereon, are removed from thecentering fixture unit, inverted and mated with second mold halveswhich, at an appropriate time earlier, have had a selected quantity ofreacting polyurea prepolymer and curing agent introduced therein tocommence gelling.

Similarly, U.S. Pat. Nos. 5,006,297 and 5,334,673 both also disclosesuitable molding techniques that may be utilized to apply the castablereactive liquids employed in the present invention.

However, golf balls of the invention may be made by any known techniqueto those skilled in the art.

Examples of yet other materials which may be suitable for incorporatingand coordinating in order to target and achieve desired playingcharacteristics or feel include plasticized thermoplastics,polyalkenamer compositions, polyester-based thermoplastic elastomerscontaining plasticizers, transparent or plasticized polyamides, thiolenecompositions, poly-amide and anhydride-modified polyolefins, organicacid-modified polymers, and the like.

Meanwhile, the dimensions of each golf ball component such as thediameter of the core and respective thicknesses of the intermediatelayer (s), cover layer(s) and coating layer(s) may be selected andcoordinated for targeting and achieving desired playing characteristicsor feel. Golf balls made in accordance with this invention can be of anysize, although the USGA requires that golf balls used in competitionhave a diameter of at least 1.68 inches. For play outside of UnitedStates Golf Association (USGA) rules, the golf balls can be of a smallersize. Normally, golf balls are manufactured in accordance with USGArequirements and have a diameter in the range of about 1.68 to about1.80 inches. Also, the USGA has established a maximum weight of 45.93 g(1.62 ounces) for golf balls. For play outside of USGA rules, the golfballs can be heavier.

Golf balls having various constructions may be made in accordance withthis invention. For example, golf balls having one-piece, two-piece,three-piece, four-piece, and five or more-piece constructions, with theterm “piece” referring to any core, cover or intermediate layer of agolf ball construction, may be made. The term, “layer” as used hereinmeans generally any spherical portion of the golf ball.

In one version, a one-piece ball is made using the inventive compositionas the entire golf ball excluding any paint or coating and indiciaapplied thereon. In a second version, a two-piece ball comprising asingle core and a single cover layer is made.

In a third version, a three-piece golf ball contains a dual-layered coreand a single-layered cover. The dual-core includes an inner core(center) and surrounding outer core layer. In another version, athree-piece ball contains a single core layer and two cover layers. Inyet another version, a four-piece golf ball contains a dual-core anddual-cover (inner cover layer and outer cover layer).

In yet another construction, a four-piece or five-piece golf ballcontains a dual-core; an inner cover layer, an intermediate cover layer,and an outer cover layer. In still another construction, a five-pieceball is made containing a three-layered core with an innermost corelayer (or center), an intermediate core layer, and outer core layer, anda two-layered cover with an inner and outer cover layer.

The diameter and thickness of the different layers along with propertiessuch as hardness and compression may vary depending upon theconstruction and desired playing performance properties of the golfball. Any one or more of the layers of any of the one, two, three, four,or five, or more-piece (layered) balls described above may comprise orconsist of a completely cured stepwise-elongated thermoset layer formedby the method of the invention. That is, any of the layers in the coreassembly (for example, inner (center), intermediate, and/or outer corelayers), and/or any of the layers in the cover assembly (for example,inner, intermediate, and/or outer cover layers) may comprise or consistof a completely cured stepwise-elongated thermoset layer formed by themethod of the invention.

Meanwhile, the core may have an overall diameter of from about 1.47inches (in.) to about 1.62 in., with outer core layers havingthicknesses of up to 0.400 or greater; intermediate/casing layer(s)having a thicknesses, for example, of from about 0.025 in. to about0.057 in.; the core and intermediate/casing layer, combined, having anouter diameter of from about 1.57 in. to about 1.65 in.; covers having athicknesses of from about 0.015 in. to about 0.055 in.; and coatinglayers having a combined thickness of from about 0.1 μm to about 100 μm,or from about 2 μm to about 50 μm, or from about 2 μm to about 30 μm.Meanwhile, each coating layer may have a thickness of from about 0.1 μmto about 50 μm, or from about 0.1 μm to about 25 μm, or from about 0.1μm to about 14 μm, or from about 2 μm to about 9 μm, for example.

In some embodiments, the core may have an overall diameter within arange having a lower limit of 0.500 or 0.700 or 0.750 or 0.800 or 0.850or 0.900 or 0.950 or 1.000 or 1.100 or 1.150 or 1.200 or 1.250 or 1.300or 1.350 or 1.400 or 1.450 or 1.500 or 1.600 or 1.610 inches and anupper limit of 1.620 or 1.630 or 1.640 inches. In a particularembodiment, the core is a multi-layer core having an overall diameterwithin a range having a lower limit of 0.500 or 0.700 or 0.750 or 0.800or 0.850 or 0.900 or 0.950 or 1.000 or 1.100 or 1.150 or 1.200 inchesand an upper limit of 1.250 or 1.300 or 1.350 or 1.400 or 1.450 or 1.500or 1.600 or 1.610 or 1.620 or 1.630 or 1.640 inches. In anotherparticular embodiment, the multi-layer core has an overall diameterwithin a range having a lower limit of 0.500 or 0.700 or 0.750 inchesand an upper limit of 0.800 or 0.850 or 0.900 or 0.950 or 1.000 or 1.100or 1.150 or 1.200 or 1.250 or 1.300 or 1.350 or 1.400 or 1.450 or 1.500or 1.600 or 1.610 or 1.620 or 1.630 or 1.640 inches. In anotherparticular embodiment, the multi-layer core has an overall diameter of1.500 inches or 1.510 inches or 1.530 inches or 1.550 inches or 1.570inches or 1.580 inches or 1.590 inches or 1.600 inches or 1.610 inchesor 1.620 inches.

The inner core can have an overall diameter of 0.500 inches or greater,or 0.700 inches or greater, or 1.00 inches or greater, or 1.250 inchesor greater, or 1.350 inches or greater, or 1.390 inches or greater, or1.450 inches or greater, or an overall diameter within a range having alower limit of 0.250 or 0.500 or 0.750 or 1.000 or 1.250 or 1.350 or1.390 or 1.400 or 1.440 inches and an upper limit of 1.460 or 1.490 or1.500 or 1.550 or 1.580 or 1.600 inches, or an overall diameter within arange having a lower limit of 0.250 or 0.300 or 0.350 or 0.400 or 0.500or 0.550 or 0.600 or 0.650 or 0.700 inches and an upper limit of 0.750or 0.800 or 0.900 or 0.950 or 1.000 or 1.100 or 1.150 or 1.200 or 1.250or 1.300 or 1.350 or 1.400 inches. In one embodiment, the inner coreconsists of a single layer formed from a thermoset rubber composition.In another embodiment, the inner core consists of two layers, each ofwhich is formed from the same or different thermoset rubbercompositions. In another embodiment, the inner core comprises three ormore layers, each of which is formed from the same or differentthermoset rubber compositions. In another embodiment, the inner coreconsists of a single layer formed from a thermoplastic composition. Inanother embodiment, the inner core consists of two layers, each of whichis formed from the same or different thermoplastic compositions. Inanother embodiment, the inner core comprises three or more layers, eachof which is formed from the same or different thermoplasticcompositions. In a particular embodiment, the inner core has one or moreof the following properties:

-   a) a center hardness within a range having a lower limit of 20 or 25    or 30 or 35 or 40 or 45 or 50 or 55 Shore C and an upper limit of 60    or 65 or 70 or 75 or 90 Shore C;-   b) an outer surface hardness within a range having a lower limit of    20 or 50 or 70 or 75 Shore C and an upper limit of 75 or 80 or 85 or    90 or 95 Shore C;-   c) a negative hardness gradient, a zero hardness gradient, or a    positive hardness gradient of up to 45 Shore C; and-   d) an overall compression of 90 or less, or 80 or less, or 70 or    less, or 60 or less, or 50 or less, or 40 or less, or 20 or less, or    a compression within a range having a lower limit of 10 or 20 or 30    or 35 or 40 and an upper limit of 50 or 60 or 70 or 80 or 90.

An intermediate core layer can have an overall thickness within a rangehaving a lower limit of 0.005 or 0.010 or 0.015 or 0.020 or 0.025 or0.030 or 0.035 or 0.040 or 0.045 inches and an upper limit of 0.050 or0.055 or 0.060 or 0.065 or 0.070 or 0.075 or 0.080 or 0.090 or 0.100inches. In one embodiment, the intermediate core consists of a singlelayer formed from a thermoset rubber composition. In another embodiment,the intermediate core consists of two layers, each of which is formedfrom the same or different thermoset rubber compositions. In anotherembodiment, the intermediate core comprises three or more layers, eachof which is formed from the same or different thermoset rubbercompositions. In another embodiment, the intermediate core consists of asingle layer formed from a thermoplastic composition. In anotherembodiment, the intermediate core consists of two layers, each of whichis formed from the same or different thermoplastic compositions. Inanother embodiment, the intermediate core comprises three or morelayers, each of which is formed from the same or different thermoplasticcompositions. In a particular embodiment, the intermediate core has oneor more of the following properties:

-   a) a surface hardness of 25 Shore C or greater, or 40 Shore C or    greater, or a surface hardness within a range having a lower limit    of 25 or 30 or 35 Shore C and an upper limit of 80 or 85 Shore C;-   b) a surface hardness of 60 Shore D or less, or less than 60 Shore    D, or 55 Shore D or less, or less than 55 Shore D;-   c) a surface hardness within a range having a lower limit of 20 or    30 or 35 or 45 Shore D and an upper limit of 55 or 60 or 65 Shore D;-   d) a surface hardness of greater than 60 Shore D;-   e) a surface hardness greater than the surface hardness of both the    inner core and the outer core.

The outer core layer can have an overall thickness within a range havinga lower limit of 0.010 or 0.020 or 0.025 or 0.030 or 0.035 inches and anupper limit of 0.040 or 0.070 or 0.075 or 0.080 or 0.100 or 0.150inches, or an overall thickness within a range having a lower limit of0.025 or 0.050 or 0.100 or 0.150 or 0.160 or 0.170 or 0.200 inches andan upper limit of 0.225 or 0.250 or 0.275 or 0.300 or 0.325 or 0.350 or0.400 or 0.450 or greater than 0.450 inches. The outer core layer mayalternatively have a thickness of greater than 0.10 inches, or 0.20inches or greater, or greater than 0.20 inches, or 0.30 inches orgreater, or greater than 0.30 inches, or 0.35 inches or greater, orgreater than 0.35 inches, or 0.40 inches or greater, or greater than0.40 inches, or 0.45 inches or greater, or greater than 0.45 inches, ora thickness within a range having a lower limit of 0.005 or 0.010 or0.015 or 0.020 or 0.025 or 0.030 or 0.035 or 0.040 or 0.045 or 0.050 or0.055 or 0.060 or 0.065 or 0.070 or 0.075 or 0.080 or 0.090 or 0.100 or0.200 or 0.250 inches and an upper limit of 0.300 or 0.350 or 0.400 or0.450 or 0.500 inches.

In one embodiment, the outer core consists of a single layer formed froma thermoset rubber composition. In another embodiment, the outer coreconsists of two layers, each of which is formed from the same ordifferent thermoset rubber compositions. In another embodiment, theouter core comprises three or more layers, each of which is formed fromthe same or different thermoset rubber compositions. In anotherembodiment, the outer core consists of a single layer formed from athermoplastic composition. In another embodiment, the outer coreconsists of two layers, each of which is formed from the same ordifferent thermoplastic compositions. In another embodiment, the outercore comprises three or more layers, each of which is formed from thesame or different thermoplastic compositions. In a particularembodiment, the outer core has one or more of the following properties:

-   a) a thickness of 0.035 inches or 0.040 inches or 0.045 inches or    0.050 inches or 0.055 inches or 0.060 inches or 0.065 inches;-   b) a surface hardness of 45 Shore C or greater, or 70 Shore C or    greater, or 75 Shore C or greater, or 80 Shore C or greater, or a    surface hardness within a range having a lower limit of 45 or 70 or    80 Shore C and an upper limit of 90 or 95 Shore C;-   c) a surface hardness greater than the surface hardness of the inner    core;-   d) a surface hardness less than the surface hardness of the inner    core;-   e) a surface hardness of 20 Shore C or greater, or 30 Shore C or    greater, or 35 Shore C or greater, or 40 Shore C or greater, or a    surface hardness within a range having a lower limit of 20 or 30 or    35 or 40 or 50 Shore C and an upper limit of 60 or 70 or 80 Shore C;-   f) a surface hardness within a range having a lower limit of 50 or    55 or 60 or 62 or 65 Shore D and an upper limit of 65 or 70 Shore D;-   g) is formed from a rubber composition selected from those disclosed    in U.S. Patent Application Publication Nos. 2009/0011857 and    2009/0011862, the entire disclosures of which are hereby    incorporated herein by reference.

The multi-layer core is enclosed with a cover, which may be a single-,dual-, or multi-layer cover, preferably having an overall thicknesswithin a range having a lower limit of 0.010 or 0.020 or 0.025 or 0.030or 0.040 or 0.045 inches and an upper limit of 0.050 or 0.060 or 0.070or 0.075 or 0.080 or 0.090 or 0.100 or 0.150 or 0.200 or 0.300 or 0.500inches. In a particular embodiment, the cover is a single layer having athickness of from 0.010 or 0.020 or 0.025 inches to 0.035 or 0.040 or0.050 inches. In another particular embodiment, the cover consists of aninner cover layer having a thickness of from 0.010 or 0.020 or 0.025inches to 0.035 or 0.050 inches and an outer cover layer having athickness of from 0.010 or 0.020 or 0.025 inches to 0.035 or 0.040inches.

In one embodiment, the cover is a single layer having a surface hardnessof 60 Shore D or greater, or 65 Shore D or greater. In a particularaspect of this embodiment, the cover is formed from a composition havinga material hardness of 60 Shore D or greater, or 65 Shore D or greater.

In another particular embodiment, the cover is a single layer having athickness of from 0.010 or 0.020 inches to 0.035 or 0.050 inches andformed from an ionomeric composition having a material hardness of from60 or 62 or 65 Shore D to 65 or 70 or 72 Shore D.

In another particular embodiment, the cover is a single layer having athickness of from 0.010 or 0.025 inches to 0.035 or 0.040 inches andformed from a thermoplastic composition selected from ionomer-,polyurethane-, and polyurea-based compositions having a materialhardness of 62 Shore D or less, or less than 62 Shore D, or 60 Shore Dor less, or less than 60 Shore D, or 55 Shore D or less, or less than 55Shore D.

In another particular embodiment, the cover is a single layer having athickness of from 0.010 or 0.025 inches to 0.035 or 0.040 inches andformed from a thermosetting polyurethane- or polyurea-based compositionhaving a material hardness of 62 Shore D or less, or less than 62 ShoreD, or 60 Shore D or less, or less than 60 Shore D, or 55 Shore D orless, or less than 55 Shore D.

In another particular embodiment, the cover comprises an inner coverlayer formed from an ionomeric composition and an outer cover layerformed from a thermosetting polyurethane- or polyurea-based composition.The inner cover layer composition preferably has a material hardness offrom 60 or 62 or 65 Shore D to 65 or 70 or 72 Shore D. The inner coverlayer preferably has a thickness within a range having a lower limit of0.010 or 0.020 or 0.030 inches and an upper limit of 0.035 or 0.040 or0.050 inches. The outer cover layer composition preferably has amaterial hardness of 62 Shore D or less, or less than 62 Shore D, or 60Shore D or less, or less than 60 Shore D, or 55 Shore D or less, or lessthan 55 Shore D. The outer cover layer preferably has a thickness withina range having a lower limit of 0.010 or 0.020 or 0.025 inches and anupper limit of 0.035 or 0.040 or 0.050 inches.

In another particular embodiment, the cover comprises an inner coverlayer formed from an ionomeric composition and an outer cover layerformed from a thermoplastic composition selected from ionomer-,polyurethane-, and polyurea-based compositions. The inner cover layercomposition preferably has a material hardness of from 60 or 62 or 65Shore D to 65 or 70 or 72 Shore D. The inner cover layer preferably hasa thickness within a range having a lower limit of 0.010 or 0.020 or0.030 inches and an upper limit of 0.035 or 0.040 or 0.050 inches. Theouter cover layer composition preferably has a material hardness of 62Shore D or less, or less than 62 Shore D, or 60 Shore D or less, or lessthan 60 Shore D, or 55 Shore D or less, or less than 55 Shore D. Theouter cover layer preferably has a thickness within a range having alower limit of 0.010 or 0.020 or 0.025 inches and an upper limit of0.035 or 0.040 or 0.050 inches.

In another particular embodiment, the cover is a dual- or multi-layercover including an inner or intermediate cover layer formed from anionomeric composition and an outer cover layer formed from apolyurethane- or polyurea-based composition. The ionomeric layerpreferably has a surface hardness of 70 Shore D or less, or 65 Shore Dor less, or less than 65 Shore D, or a Shore D hardness of from 50 to65, or a Shore D hardness of from 57 to 60, or a Shore D hardness of 58,and a thickness within a range having a lower limit of 0.010 or 0.020 or0.030 inches and an upper limit of 0.045 or 0.080 or 0.120 inches. Theouter cover layer is preferably formed from a castable or reactioninjection moldable polyurethane, polyurea, or copolymer or hybrid ofpolyurethane/polyurea. Such cover material is preferably thermosetting,but may be thermoplastic. The outer cover layer composition preferablyhas a material hardness of 85 Shore C or less, or 45 Shore D or less, or40 Shore D or less, or from 25 Shore D to 40 Shore D, or from 30 Shore Dto 40 Shore D. The outer cover layer preferably has a surface hardnesswithin a range having a lower limit of 20 or 30 or 35 or 40 Shore D andan upper limit of 52 or 58 or 60 or 65 or 70 or 72 or 75 Shore D. Theouter cover layer preferably has a thickness within a range having alower limit of 0.010 or 0.015 or 0.025 inches and an upper limit of0.035 or 0.040 or 0.045 or 0.050 or 0.055 or 0.075 or 0.080 or 0.115inches.

In another particular embodiment, the cover comprises an inner coverlayer formed from an ionomeric composition and an outer cover layerformed from a thermosetting polyurethane- or polyurea-based composition.The inner cover layer composition preferably has a material hardness offrom 60 or 62 or 65 Shore D to 65 or 70 or 72 Shore D. The inner coverlayer preferably has a thickness within a range having a lower limit of0.010 or 0.020 or 0.030 inches and an upper limit of 0.035 or 0.040 or0.050 inches. The outer cover layer composition preferably has amaterial hardness of 62 Shore D or less, or less than 62 Shore D, or 60Shore D or less, or less than 60 Shore D, or 55 Shore D or less, or lessthan 55 Shore D. The outer cover layer preferably has a thickness withina range having a lower limit of 0.010 or 0.020 or 0.025 inches and anupper limit of 0.035 or 0.040 or 0.050 inches.

In another particular embodiment, the cover comprises an inner coverlayer formed from an ionomeric composition and an outer cover layerformed from a thermoplastic composition selected from ionomer-,polyurethane-, and polyurea-based compositions. The inner cover layercomposition preferably has a material hardness of from 60 or 62 or 65Shore D to 65 or 70 or 72 Shore D. The inner cover layer preferably hasa thickness within a range having a lower limit of 0.010 or 0.020 or0.030 inches and an upper limit of 0.035 or 0.040 or 0.050 inches. Theouter cover layer composition preferably has a material hardness of 62Shore D or less, or less than 62 Shore D, or 60 Shore D or less, or lessthan 60 Shore D, or 55 Shore D or less, or less than 55 Shore D. Theouter cover layer preferably has a thickness within a range having alower limit of 0.010 or 0.020 or 0.025 inches and an upper limit of0.035 or 0.040 or 0.050 inches.

In another particular embodiment, the cover is a dual- or multi-layercover including an inner or intermediate cover layer formed from anionomeric composition and an outer cover layer formed from apolyurethane- or polyurea-based composition. The ionomeric layerpreferably has a surface hardness of 70 Shore D or less, or 65 Shore Dor less, or less than 65 Shore D, or a Shore D hardness of from 50 to65, or a Shore D hardness of from 57 to 60, or a Shore D hardness of 58,and a thickness within a range having a lower limit of 0.010 or 0.020 or0.030 inches and an upper limit of 0.045 or 0.080 or 0.120 inches. Theouter cover layer is preferably formed from a castable or reactioninjection moldable polyurethane, polyurea, or copolymer or hybrid ofpolyurethane/polyurea. Such cover material is preferably thermosetting,but may be thermoplastic. The outer cover layer composition preferablyhas a material hardness of 85 Shore C or less, or 45 Shore D or less, or40 Shore D or less, or from 25 Shore D to 40 Shore D, or from 30 Shore Dto 40 Shore D. The outer cover layer preferably has a surface hardnesswithin a range having a lower limit of 20 or 30 or 35 or 40 Shore D andan upper limit of 52 or 58 or 60 or 65 or 70 or 72 or 75 Shore D. Theouter cover layer preferably has a thickness within a range having alower limit of 0.010 or 0.015 or 0.025 inches and an upper limit of0.035 or 0.040 or 0.045 or 0.050 or 0.055 or 0.075 or 0.080 or 0.115inches.

The CoR of a particular golf ball subassembly may be targeted, forexample, to be 0.450 or greater, or 0.475 or greater, or 0.500 orgreater, or 0.525 or greater, or 0.550 or greater, or 0.575 or greater,or 0.600 or greater, or 0.625 or greater, or 0.650 or greater, or 0.675or greater, or 0.700 or greater, or 0.725 or greater, or 0.750 orgreater, or 0.800 or greater, or 0.825 or greater, or 0.850 or greater,or 0.825 or greater, or 0.850 or greater, or 0.875 or greater.Embodiments are also envisioned wherein the CoR of a particular layercan be less than 0.450.

The overall coefficient of restitution (“CoR”) of some cores of thepresent invention at 125 ft/s is at least 0.750, or at least 0.775 or atleast 0.780, or at least 0.782, or at least 0.785, or at least 0.787, orat least 0.790, or at least 0.795, or at least 0.798, or at least 0.800.Golf balls of the present invention typically have a golf ball CoR of0.700 or greater, preferably 0.750 or greater, and more preferably 0.780or greater. Golf balls of the present invention typically have acompression of 40 or greater, or a compression within a range having alower limit of 50 or 60 and an upper limit of 100 or 120. However, insome embodiments, at least one golf ball layer may have a compression ofless than 40.

Golf ball properties such as compression and hardness may be measured asfollows. For purposes of the present invention, “compression” refers toAtti compression and is measured according to a known procedure, usingan Atti compression test device, wherein a piston is used to compress aball against a spring. The travel of the piston is fixed and thedeflection of the spring is measured. The measurement of the deflectionof the spring does not begin with its contact with the ball; rather,there is an offset of approximately the first 1.25 mm (0.05 inches) ofthe spring's deflection. Very low compression cores will not cause thespring to deflect by more than 1.25 mm and therefore have a zero ornegative compression measurement. The Atti compression tester isdesigned to measure objects having a diameter of 1.680 inches; thus,smaller objects, such as golf ball cores, must be shimmed to a totalheight of 1.680 inches to obtain an accurate reading. Conversion fromAtti compression to Riehle (cores), Riehle (balls), 100 kg deflection,130-10 kg deflection or effective modulus can be carried out accordingto the formulas given in Compression by Any Other Name, Science and GolfIV, Proceedings of the World Scientific Congress of Golf (Eric Thained., Routledge, 2002).

The center hardness of a core is obtained according to the followingprocedure. The core is gently pressed into a hemispherical holder havingan internal diameter approximately slightly smaller than the diameter ofthe core, such that the core is held in place in the hemisphericalportion of the holder while concurrently leaving the geometric centralplane of the core exposed. The core is secured in the holder byfriction, such that it will not move during the cutting and grindingsteps, but the friction is not so excessive that distortion of thenatural shape of the core would result. The core is secured such thatthe parting line of the core is roughly parallel to the top of theholder. The diameter of the core is measured 90 degrees to thisorientation prior to securing. A measurement is also made from thebottom of the holder to the top of the core to provide a reference pointfor future calculations. A rough cut is made slightly above the exposedgeometric center of the core using a band saw or other appropriatecutting tool, making sure that the core does not move in the holderduring this step. The remainder of the core, still in the holder, issecured to the base plate of a surface grinding machine. The exposed‘rough’ surface is ground to a smooth, flat surface, revealing thegeometric center of the core, which can be verified by measuring theheight from the bottom of the holder to the exposed surface of the core,making sure that exactly half of the original height of the core, asmeasured above, has been removed to within ±0.004 inches. Leaving thecore in the holder, the center of the core is found with a center squareand carefully marked and the hardness is measured at the center markaccording to ASTM D-2240. Additional hardness measurements at anydistance from the center of the core can then be made by drawing a lineradially outward from the center mark, and measuring the hardness at anygiven distance along the line, typically in 2 mm increments from thecenter. The hardness at a particular distance from the center should bemeasured along at least two, preferably four, radial arms located 180°apart, or 90° apart, respectively, and then averaged. All hardnessmeasurements performed on a plane passing through the geometric centerare performed while the core is still in the holder and without havingdisturbed its orientation, such that the test surface is constantlyparallel to the bottom of the holder, and thus also parallel to theproperly aligned foot of the durometer.

Hardness points should only be measured once at any particular geometriclocation.

The surface hardness of a golf ball layer is obtained from the averageof a number of measurements taken from opposing hemispheres, taking careto avoid making measurements on the parting line of the core or onsurface defects such as holes or protrusions. Hardness measurements aremade pursuant to ASTM D-2240 “Indentation Hardness of Rubber and Plasticby Means of a Durometer.” Because of the curved surface of the golf balllayer, care must be taken to ensure that the golf ball or golf ballsubassembly is centered under the durometer indentor before a surfacehardness reading is obtained. A calibrated digital durometer, capable ofreading to 0.1 hardness units, is used for all hardness measurements.The digital durometer must be attached to and its foot made parallel tothe base of an automatic stand. The weight on the durometer and attackrate conforms to ASTM D-2240. It should be understood that there is afundamental difference between “material hardness” and “hardness asmeasured directly on a golf ball.” For purposes of the presentinvention, material hardness is measured according to ASTM D2240 andgenerally involves measuring the hardness of a flat “slab” or “button”formed of the material. Surface hardness as measured directly on a golfball (or other spherical surface) typically results in a differenthardness value. The difference in “surface hardness” and “materialhardness” values is due to several factors including, but not limitedto, ball construction (that is, core type, number of cores and/or coverlayers, and the like); ball (or sphere) diameter; and the materialcomposition of adjacent layers. It also should be understood that thetwo measurement techniques are not linearly related and, therefore, onehardness value cannot easily be correlated to the other.

It is understood that the golf balls of the invention incorporating atleast one layer of thermoset polymer composition elongated while in apartial cure state, made by the methods described and illustratedherein, represent only some of the many embodiments of the invention. Itis appreciated by those skilled in the art that various changes andadditions can be made to such golf balls without departing from thespirit and scope of this invention. It is intended that all suchembodiments be covered by the appended claims.

A golf ball of the invention may also incorporate indicia such as anysymbol, letter, group of letters, design, or the like, that can be addedto the dimpled surface of a golf ball.

It will be appreciated that any known dimple pattern may be used withany number of dimples having any shape or size. For example, the numberof dimples may be 252 to 456, or 330 to 392 and may comprise any width,depth, and edge angle. The parting line configuration of said patternmay be either a straight line or a staggered wave parting line (SWPL).

In any of these embodiments the single-layer core may be replaced with a2 or more layer core wherein at least one core layer has a hardnessgradient.

Other than in the operating examples, or unless otherwise expresslyspecified, all of the numerical ranges, amounts, values and percentagessuch as those for amounts of materials and others in the specificationmay be read as if prefaced by the word “about” even though the term“about” may not expressly appear with the value, amount or range.Accordingly, unless indicated to the contrary, the numerical parametersset forth in the specification and attached claims are approximationsthat may vary depending upon the desired properties sought to beobtained by the present invention. At the very least, and not as anattempt to limit the application of the doctrine of equivalents to thescope of the claims, each numerical parameter should at least beconstrued in light of the number of reported significant digits and byapplying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical value, however, inherently contain certainerrors necessarily resulting from the standard deviation found in theirrespective testing measurements. Furthermore, when numerical ranges ofvarying scope are set forth herein, it is contemplated that anycombination of these values inclusive of the recited values may be used.

Although the golf ball of the invention has been described herein withreference to particular means and materials, it is to be understood thatthe invention is not limited to the particulars disclosed and extends toall equivalents within the scope of the claims.

The invention claimed is:
 1. A method of making a golf ball comprising:providing a subassembly; providing a thermoset polymer composition;stepwise elongating the thermoset polymer composition by at least thesteps of: (i) stretching the thermoset polymer composition in at leastone plane while the thermoset polymer composition is in a partial curestate and before forming the thermoset polymer composition into firstand second half shells; and (ii) forming the thermoset polymercomposition into first and second half shells and elongating thethermoset polymer composition in three dimensions while the thermosetpolymer composition is in the partial cure state and before mating thefirst and second half shells about the subassembly; mating the first andsecond half shells about the subassembly and forming astepwise-elongated thermoset layer.
 2. The method of making a golf ballof claim 1, wherein the thermoset polymer composition comprises arubber-based composition comprising at least one of polybutadiene,ethylene propylene rubber (EPR), ethylene-propylene-diene rubber (EPDM),styrene-butadiene rubber, butyl rubber, halobutyl rubber, polyurethane,polyurea, acrylonitrile butadiene rubber, polychloroprene, alkylacrylate rubber, polyalkenamer, phenol formaldehyde, melamineformaldehyde, polyepoxide, polysiloxane, polyester, alkyd,polyisocyanurate, polycyanurate, polyacrylate, and combinations thereof.3. The method of making a golf ball of claim 2, wherein the thermosetpolymer composition is elongated from 10% to 200% during the partialcure state.
 4. The method of making a golf ball of claim 2, wherein thethermoset polymer composition is elongated at least 50% during thepartial cure state.
 5. The method of making a golf ball of claim 2,wherein the thermoset polymer composition is elongated at least 100%during the partial cure state.
 6. The method of making a golf ball ofclaim 2, wherein the thermoset polymer composition is elongated at least150% during the partial cure state.
 7. The method of making a golf ballof claim 2, wherein the thermoset polymer composition is elongated 200%or greater during the partial cure state.
 8. The method of making a golfball of claim 3, wherein the stepwise elongated layer comprises an outercore layer and the subassembly is an inner core layer.
 9. The method ofmaking a golf ball of claim 3, wherein the stepwise elongated layercomprises an inner cover layer and the subassembly is a core.
 10. Themethod of making a golf ball of claim 3, wherein the stepwise elongatedlayer comprises an intermediate layer disposed between the subassemblyand at least one cover layer.
 11. The method of making a golf ball ofclaim 2, wherein the step of elongating the thermoset polymercomposition in three dimensions follows forming the thermoset polymercomposition into first and second half shells.
 12. The method of makinga golf ball of claim 2, wherein the step of elongating the thermosetpolymer composition in three dimensions and the step of forming thethermoset polymer composition into first and second half shells occursimultaneously.
 13. The method of making a golf ball of claim 2, furthercomprising interrupting the partial cure state for a predeterminedduration following stretching the thermoset polymer composition insubstantially one plane and prior to elongating the thermoset polymercomposition in three dimensions.
 14. The method of making a golf ball ofclaim 2, further comprising interrupting cure of the thermoset polymercomposition for a predetermined duration while elongating the thermosetpolymer composition in three dimensions.
 15. The method of making a golfball of claim 2, wherein the first and second half shells arecompression molded about the subassembly.